Textile filament



' Nov. 5, 1963 w. R- ELLINGSEN TEXTILE FILAMENT 2 Sheets-Sheet 1 Filed Jan. 6, 1960 PIC-3.5

INVENTOR WALTER R. ELLINGSEN ATTORNEY Nov. 5, 1963 w. R. ELLmGSEN 3,109,768

TEXTILE F ILAMENT Filed Jan. 6, 1960 2 SheetsSheet 2 F|G.4 FIG5 FIG? F166 INVENTOR WALTER R. ELLINGSEN ATTORNEY United States Patent O 3,109,768 TEXTILE FILAMENT Walter El. Ellingsen, Newark, Deh, assignor to E. I. du Pont tie Nemcurs and tlonipany, Wilmington, Del., a corporation of Delaware Filed Jan. 6, 1960, Ser. No. 742 7 Claims. (El. 161177) This invention relates to novel synthetic fibers and filaments having unique optical properties and improved aesthetic qualities. More particularly, the invention relates to fibers and filaments having a pentagonal crosssectional configuration.

Fibers having various cross-sectional configurations have been prepared. Cross sections simulating ribbons, dumbbell or dogbone shapes, crenul-ated, cruciform, and Y shapes have been used in preparing textile materials which exhibit sheen, bulk, a dry hand, and the like. Recently, fabrics, e.g., hosiery, prepared from trilobal filaments which exhibit a peculiar luster highlight have become commercially available. Still a ditierent optical effect is desirable in other textile applications.

It is, therefore, an object of the present invention to provide novel fibers and filaments which are particularly adapted for use in flat fabrics, hosiery, upholstery, and the like which exhibit a unique diamond-like sparkle. Another object is to provide fabrics having a combination of unique optical properties, improved covering power, suppleness, and other aesthetic properties. A particular object is to provide filaments which reflect a substantial part of incident light in high intensity narrow beams. Other objects will be apparent from the following detailed description.

The objects of this invention are accomplished by providing a shaped article from a synthetic polymer having a pentagonal cross-sectional configuration. The sides of the pentagon are essentially straight, with three angles defined by the sides being approximately 90 each. Two of the 90 angles must be formed by the intersection of a common side with two parallel sides of essentially equal length. The other 90 angle must be located opposite the common side and is therefore [formed at the intersection of the two remaining sides. The length of the sides of the cross section is controlled by the ratio of the lengths of two lines, one extending perpendicularly from the common side to the apex of the third 90 angle, and the other extending perpendicularly from a line parallel to the common side which connects the. points of intersection of the parallel sides and the two remaining sides .to the apex of the third 90 angle. This ratio is in the range from about 1.5 to about 3.

While the cross section of the filaments of this invention must have essentially straight sides, it is to be under stood that one or any combination of the sides may be sli htly concave or convex. In addition, the apex of the pentagon may be either symmetrical-1y disposed above the common side or may be displaced either to the left or right. The corners may be either sharp or rounded as will be further described later herein.

In general, the filaments of this invention may be pre pared by extruding a molten polymer or a solution of the polymer through an orifice which provides a pentagonal shape. Spinning conditions must, of course, be varied, depending on the particular synthetic polymer being spun.

can be obtained as illustrated in FIGS. 5 and 6.

messes Patented Nov. 5, 1963 Conditions should be controlled to give filaments which have a substantially uniform cross-sectional shape along their length. Although the shape of the filaments must remain within the limits previously described, slight variations in the parameters may occur along the length of the filament or from filament-to-filament in a bundle without adversely affecting their unique properties. The denier of the filaments may vary within wide limits. Deniers in the range from 1 to 35 are usually preferred; however, deniers as high as 250 and higher may be utilized depending on the end use desired.

The present invention will be more fully understood by reference to the following detailed description and accompanying drawings, in which:

FIGURE 1 is an enlarged view of the cross section of the preferred filaments of the present invention;

FIGURE 2 is an enlarged view of an orifice of a spinneret suitable for producing filaments having the cross section shown in FIGURE 1; and

FIGURES 3 .to 7, inclusive, illustrate various modifications of the pentagonal-shaped filaments of the present invention.

Referring now to FIG. 1, the cross section consists of essentially straight sides 1-5 and has three angles A, B, and C of approximately each. Each of the sides are curved adjacent to the points of intersection to form rounded tips. Line X, which is perpendicular to side 1 bisects angle A. The cross section is symmetrical about line X. By extending sides 2, 3, 4, and 5, two points of intersections 6 and 7 are determined. Line 8, which connects these points, is parallel to side 1. Line X extends perpendicularly from line 8 to the apex of angle A.

As previously indicated, the relative lengths of the sides of the cross section are determined by the ratio of the length of line X to the line X. In the preferred embodiment, which provides maximum sparkle from the pentagonal cross section, the ratio of X/X equals 2.

Referring now to FIG. 2, the orifice from which the polymer is extruded is comprised of three rectangular, symmetrically disposed arms. Two circular orifices are in communication with one of the rams as shown in FIG. 2. The position of the circular orifices and the length of the arm to which they are connected may be varied to change the particular configuration of the filament cross section. The angle between the arms may likewise be changed when spinning various polymers or utilizing various spinning conditions, e.g., rapid quenching and the like, to insure that the two adjacent 90 angles, B and C, are formed with common side 1. Depending on the polymer being extruded, a pentagonal-shaped orifice may be used successfully as well as other modification of the orifice described above.

As previously indicated, FIGURES 3 to 7 illustrate various modifications in the cross-sectional shape of the filaments in the present invention. In FIG. 3 the common side is slightly convex, the parallel sides straight, and the remaining two sides slightly concave. In FIG. 4 the configuration is unsymmetrical with the third 90 angle being displaced above and away from the middle of the common side. Under certain circumstances, for example when a pentagonal extrusion orifice is used with rapid quenching, cross sections having fairly sharp points In addition, a substantial proportion of the sides may be curved to provide the rounded tips as illustrated in FIG. 7. It is necessary, however, that the common side have a substantial portion which is essentially straight.

The following example further illustrates the preparation of filaments and fabrics according .to the present invention:

Polyhexamethylene adipamide is prepared according to the process described in US. Patent 2,130,523. The polymer is melt spun to provide 15-denier monofilarnents having the cross-sectional configuration shown in FIG. 1.

Ladies full-fashioned hosiery is prepared on a 60 gauge, 4-position, hosiery knitting machine manufactured by Robert Reiner, Inc., Weehawken, New Jersey. Two ends of the monofilament yarn are combined for the welt fabric and for the splicing, with the body of the stocking being of monofilament construction. The hosiery is seamed, pre-boarded, scoured, and dyed to a gold shade. Finishing and postboarding is then accomplished. The resulting gold-colored hosiery presents a dazzling diamond-like sparkle. The color clarity is excellent.

Hosiery exhibiting this diamond-like sparkle can also be prepared in seamless or tricot knit construction. In addition, yarn counts such as 14/2, 15/3, 17/2, /1, 7/1, 21/3, 30/10, and 40/13 may be used. The color of dye used'is', of course, a matter of choice.

Staple fiber or continuousfilaments having the crosssectional configuration previously described may be prepared from a variety of synthetic fibers. Among the most important polymers are the polyamides, such as polyhexamethylene adipamide, polyhexamethylene sebacamide, polycaproamide, polyxylylene azelamide, polyoctamethylene oxalamide, polypyrrolidone, polymetaphenylene is-ophthalamide, polymetaphenylene adipamide; copolyamides, and irradiation grafted polyamides; the polyesters and copolyesters such as the condensation products of ethylene glycol with tereph-thalic acid, ethylene glycol with a 98/2 mixture of terephthalic/S- (sodium sulfo)-isophthalic acids, ethylene glycol with a 90/10 mixture of terepht-halic and isophthalic acids, polyesters derived from 2,2-bis(4 hydroxyphenyl) propane, and trans p-hexahydroxylylene glycol with terephthalic acid; acryl'onitrile polymers and copolymers such as polyacrylonitrile, copolymers and terpolymers of acrylonitrile with vinyl pyridine, vinylidene chloride, vinyl chloride, or methyl acrylate; vinyl chloride polymers and copolymers, vinylidene chloride polymers and copolymers, polyurethanes, e.g., those described in French Patent 1,172,566, polyesteramides, polyethylenes, polypropylenes (especially linear polypropylene), polycarbo-nates such as those derived from 2,2-bis(4-hydroxyphenyl) propane, fluorinated ethylene polymers and copolymers such as polymers of tetrafluoroethylene, hexafiuoropropene, and monochlorotrifluoroethylene; composite filaments such as, for example, a sheath of polyamide around a core of polyester as described in the application of Breen, Serial No. 621,443, filed Novemher 9, 1956, now abandoned, of which Serial No. 771,- 676, filed November 3, .1958, and now Patent No. 3,038,- 236, is a continuation-in-part, and two acrylonitrile polymers differing in ionizable group content spun as a sheath and core 'as described in the application of Taylor, Serial No. 640,722, filed February 18, 1957, now abon- .doned, of which Serial No. 771,677, filed November 3,

Mixtures of the above fibers as Well as blends containing a major proportion of the synthetic fibers of this invention with a minor proportion of natural fibers of synthetic fibers of other cross sect-ions may be used to prepare fabrics. The filaments may be spun in the form 4 of tow, monofilament yarn, multifilament yarn, roving or the like.

The filaments of this invention are particularly useful in bulked form. Bulking may be conveniently achieved by a number of methods. For example, a particularly desirable bulking process is described in the copending application of Breen and Lauterbach, Serial No. 698,- 103, filed November 22, 1957. The novel filaments of this invention are peculiarly adaptable to being processed by the bulking process of the just mentioned application. The filaments of this invention may also be treated according to the process described in the copending application of Breen and Sussman, Serial No. 810,671, filed May 4, 1959, to provide desirable products.

Obviously, slight variations in the configuration of the filaments of this invention may occur in spinning without impairing their unique and desirable properties; Slight distortions may also be introduced in the filament during processing such as drawing, crimping, twisting, dyeing, bulking, and the like.

Known additives may be included in the polymers,

e.g., dyes, pigments, delusterants, and the like may be utilized. Small amounts of titanium dioxide, for example up to about 2%, reduce the fabric sheen but do not materially affect the sparkle obtained from the cross sections of this invention.

- The chief advantage provided by the fibers, filaments, yarns, and fabrics of this invention is the unique combination of striking optical properties and improved aesthetic properties. In particular, a unique sparkle is exhibited' which has heretofore not been possible to obtain from fibers of known cross sections. Fabrics constructed of the fibers having pentagonal cross sections described herein, in addition to the unique sparkle exhibit desirable suppleness, drape, and fabric hand. The fabrics prepared from the filaments of this invention also have greater covering power than those prepared from fibers having round cross sections.

The novel fibers and filaments of this invention may be employed to produce a Wide variety of different types of woven, knitted, and non-woven fabrics, including both apparel and industrial textile productsf Specific examples of these products include shintings, suitings, sweaters, dress and blouse fabrics, hosiery, sheeting, lingerie, taifetas, georgetes, sand-crepes, tissue-failles, fouilards, broadcloths, batistes, rainwear, surah, tricot, tulles, circular knitted goods, satins, ohiffons, Sheers, wash wear fabrics, 'crepes, casement fabrics, upholstery, carpets, filter cloths, ducks, belt-ings, webbing, braids, cordage and twine, fiber-reinforced laminates, tire cord, coated fabrics, pile fabrics, stuffing materials, floor covering, tiles, batts, felts, furs, velvets, and the like.

As many widely different embodiments of this invention may be made without departing from the spirit and scope thereof, it is to be understood that this invention is not to be limited to the specific embodiments thereof except as defined in the appended claims.

I claim:

1. A textile filament having an essentially straight-sided pentagonal-shaped cross section prepared from a synthetic fiber-forming polymer capable of reflecting a substantial portion of incident light in high intensity narrow beams, said cross section having three angles of approximately each, two of said angles being formed by the intersection of a common side with two parallel sides of essentially equal length, the other of said angles being opposite said common side and being formed at the intersection of the two remaining sides, the length of the sides of said cross section being controlled by the ratio of the lengths of two lines, the first of said lines extending perpendicularly from said common side to the apex of said other angle and the second of said lines extending perpendiculanly from a line parallel to said common side which connects the points of intersection of said parallel sides and the said remaining sides to the apex of said other angle, the ratio of the length of said first tline to the length of said second line being from about 1.5 to about 3.

2. The filament of claim 1 wherein said cross section is symmetrical about a line bisecting said other angle.

3. The filament of claim 2 wherein said ratio is about 2.

4. The filament of claim 1 wherein said sides are curved adjacent the points of intersection to form rounded tips.

5. A textile fabric prepared from the filaments of claim 1.

6. The filament of claim 1 wherein said polymer is a polyamide.

7. The filament of olaim 1 wherein said polymer is a polyester.

References Cited in the file of this patent UNITED STATES PATENTS 1,576,897 BOizard Mar. 16, 1926 6 1,773,969 Dreyfus et a1 Aug. 26, 1930 1,902,953 Hazell Mar. 28, 1933 1,944,378 Thenoz Jan. 23, 1934 2,041,798 Taylor May 26, 1936 2,291,873 Brubaker Aug. 4, 1942 2,317,485 Rider Apr. 27, 1943 2,538,918 Sejoumet et al. Jan. 23, 1951 2,939,201 Holland June 7, 1960 FOREIGN PATENTS 401,160 Great Britain Nov. 9, 1933 OTHER REFERENCES Sears et al.: College Physics, Addison-Wesley Press, Inc., Cambridge 42, Mass, 2nd edition, 1952 (page 728 of interest only). (Copy available in Division 21.) 

1. A TEXTILE FILAMENT HAVING AN ESSENTIALLY STRAIGHT-SIDED PENTAGONAL-SHAPED CROSS SECTION PREPARED FROM A SYNTHETIC FIBER-FORMING POLYMER CAPABLE OF REFLECTING A SUBSTANTIAL PORTION OF INCIDENT LIGHT IN HIGH INTENSITY NARROW BEAMS, SAID CROSS SECTION HAVING THREE ANGLES OF APPROXIMATELY 90* EACH, TWO OF SAID ANGLES BEING FORMED BY THE INTERSECTION OF A COMMON SIDE WITH TWO PARALLEL SIDES OF ESSENTIALLY EQUAL LENGTH, THE OTHER OF SAID ANGLES BEING OPPOSITE SAID COMMON SIDE AND BEING FORMED AT THE INTERSECTION OF THE TWO REMAINING SIDES, THE LENGTH OF THE SIDES OF SAID CROSS SECTION BEING CONTROLLED BY THE RATIO OF THE LENGTHS OF TWO LINES, THE FIRST OF SAID LINES EXTENDING PERPENDICULARLY FROM SAID COMMON SIDE TO THE APEX OF SAID OTHER ANGLE AND THE SECOND OF SAID LINES EXTENDING PERPENDICULARLY FROM A LINE PARALLEL TO SAID COMMON SIDE WHICH CONNECTS THE POINTS OF INTERSECTION OF SAID PARALLEL SIDES AND THE SAID REMAINING SIDES TO THE APEX OF SAID OTHER ANGLE, THE RATIO OF THE LENGTH OF SAID FIRST LINE TO THE LENGTH OF SAID SECOND LINE BEING FROM ABOUT 1.5 TO ABOUT
 3. 